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 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022
Index No: ET-02-13

Power Factor Improvement of Industrial Loads

using a Capacitor Bank and a Solar PV System
Madhushika Kalhari Hasitha Eranda Bandara Sampath Ediriweera
Department of Electrotechnology Department of Electrotechnology Department of Electrotechnology
Wayamba University of Sri Lanka Wayamba University of Sri Lanka Wayamba University of Sri Lanka
Kuliyapitiya, Sri Lanka Kuliyapitiya, Sri Lanka Kuliyapitiya, Sri Lanka
kalharimadhushika120@[Link] hasithae@[Link] [Link]@[Link]

Abstract—A significant portion of the cost of higher electricity bill for an end user for the same amount of
manufacturing in the industry is related to electrical power. An active power [3].
electrical system with a low power factor is typically less
effective and may also be less profitable for end users and Therefore, finding the most cost-effective strategy for
system operators. Therefore, power factor correction is improving the power factor for industrial power users is
essential for effective system performance and for lowering the critical. The literature contains reports of numerous studies
cost of electricity. This paper presents a study on the technical on power factor improvement [5]–[10]. Theoretically and
and financial benefits of power factor improvement, which is economically, corrective measures, including installing shunt
supported by a real-world industrial load with a combination capacitor banks and using onsite synchronous machines to
of a capacitor bank and a solar photovoltaic system. A load supply reactive power locally, were examined [8]–[10]. The
flow software is used to model and analyse the electrical system size of the capacitor bank is determined by the type of
of the site with the dynamic loads. The capacitor bank’s electrical load in the plant [11]. Three strategies such as
connected duration is calculated by keeping track of the power individual compensation, group compensation, and central
factor, active power, and reactive power values during the day. compensation, were suggested for locating the capacitors
The capacitor bank is sized to meet the reactive power needed [11], [12]. By employing various energy-saving techniques,
at night. By examining the 24-hour solar irradiance data at the industrial plants can reduce their overall energy use.
location, the solar system is designed to meet the peak active
Demand-Side Management techniques (DSM) assist
power consumption of the site. The voltage source converter
industrial users in lowering production costs and increasing
coupled to the solar system is adjusted to produce the reactive
power required to maintain the power factor during the day. market competition. Through conservation measures and
The findings demonstrate that the suggested 40 kvar capacitor demand efficiency, DSM techniques assist consumers in
bank and 553 kW solar system successfully increase power lowering their energy consumption expenses [13].
factor by 39%. A simple payback period for the suggested Distributed energy resources based on solar PV are one such
system is six years, and it also results in monthly savings of method of DSM techniques
905806 LKR. In summary, most conventional power factor
improvement methods are based on capacitor bank
Keywords— Capacitor Bank, Power Factor Improvement,
Reactive power, Solar Photovoltaic System, Voltage Source installations [10]–[12]. They have been able to improve the
Converter power factor. However, the flexibility of controlling the
capacitor bank to regulate the power factor is lower and can
I. INTRODUCTION result in over and under-correction of the power factor. Also,
the capacitor bank alone cannot lower the electricity bill of
Power quality refers to the efficiency of the electrical grid
industrial loads. Thus, it is necessary to introduce a technique
in supplying power to customers and the capability of the
to regulate the power factor of industrial loads while
equipment to use the supplied power. High power quality is
minimizing the electricity charges(for kWh consumption).
indicated by a power factor closer to one. A lower power
Therefore, this paper explains an investigation on improving
factor worsens the power quality and increases the cost of
the power factor by combining a capacitor bank and solar
electricity. There are three basic types of consumers in Sri
panels in a garment factory in Sri Lanka named ”Miami
Lanka; 1)Domestic, 2) Industrial, and 3)Commercial. Any
Exports (Pvt) Ltd” with the goal of minimizing maximum
industrial process relies heavily on the quality of the
demand and electricity cost by modeling and analyzing the
electrical power, which is vital in terms of economic and
company’s electrical system and observing the electricity
technological advantages [1]–[4].
usage. Section II discusses the overview of the factory, and
In contrast to residential loads, most commercial and section III explains the details of system modeling and
industrial buildings have high inductive loads, such as demand analysis. Power factor correction methods proposed
electric motors, ventilation, refrigeration, air conditioning, for the factory are explained in Section IV. Next, section V
and fluorescent lighting. The power supply is distorted, and presents the results and discussion, and finally, section VI
the power factor is reduced due to these installations and concludes the paper.
their functioning. A plant with a poor power factor
experiences significant losses, and it can cause a thermal II. OVERVIEW OF THE FACTORY
problem in the switchgear and a negative impact on the cost Miami Exports is a leading manufacturer of BAM
of electricity, energy waste, and the lifespan of the electrical Holdings, a Sri Lankan corporation with various commercial
equipment. On the other hand, a low power factor results in a interests in the garment industry, founded in 1980. It
ISSN 2756-9160 Page 6
 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022
specializes in the production and export of children’s
clothing. Miami Exports has several sub-factories, and the
factory in Ranna, in the southern province of Sri Lanka, is
selected to conduct the research. Fig.1 shows the basic layout
of the company.

Fig. 3. The basic layout of plant two

The canteen uses two 0.5 kW motors for coconut

scraping, two 1.5 kW hot water boilers, and four fridges. The
air compressor unit consists of two 75 kW induction motors
and a 30 kW induction motor to provide compressed air for
machines.
Fig. 1. The basic layout of the factory
Mainly plant two has fabric stores, an inspection section,
The factory has two plants, namely, Plant one and Plant a sewing section, an ironing section, a packing section, and a
two. It takes electricity from the Ceylon Electricity finishing section. The sewing Department has six production
Board(CEB) through a 630kVA transformer. In case of a lines, and each has fifty servo motors. Each fabric and
power cut, plant one is powered by a 500 kVA generator, inspection section has three 0.5 HP induction motors.
while plant two is powered by a 250 kVA generator. Plants
one and two take the electricity through the changeover TABLE I. SECTION-WISE ELECTRICAL APPLIANCES
switches separately. Number of Machines
Section Machines
Mainly, plant one has fabric stores, an inspection section, Plant 1 Plant 2
a sewing Department, an ironing section, a packing section, Fabric
Exhaust fan - 2
and a finishing section. The basic layout of plant one is given Stores
Fabric Fabric Inspection machine 1 1
in Fig.2. The cutting section and the canteen are common for Inspection
both plants one and two. The sewing Department has a new Auto cutter machine 2 -
production area, and production lines one, two, and three. Spreader machine 3 -
The cutting building has three floors. The ground and first Cutting Plotter machine 2 -
floors are used for the cutting section, and the second floor is Fusing machine 2 -
used for the fabric stores and inspection. The cutting section AC machine(Split) 2 -
has two auto-cutter machines with 15 kW induction motors. Sewing machine 300 280
Heat seal machine 4 4
Other than that, it has fusing machines and spreader Sewing AC machine(Split) 10 6
machines. Exhaust fans with 0.5 HP induction motors are Department Air compressor 2 2
used in the sewing Department. Most machinery and Mini boiler 5 5
electrical equipment are sewing machines, most of which are Bottle iron 10 8
powered by servo motors, while induction motors power Exhaust fan 24 -
Steam boiler(Fuel) 1 1
others. The ironing section has ironing tables with 0.55 kW Ironing Exhaust fan - 1
induction motors. Iron table 38 19
Industrial standing fan - 3
Threat sucker machine 1 2
Packing Metal detector machine 1 1
Exhaust fan - 1
Coconut scraping machine 2 -
Canteen Hot water boiler 2 -
Fridge 4 -

TABLE II. CAPACITY OF ELECTRICAL APPLIANCES

Load Rating (kW)

Fig. 2. The basic layout of plant one Exhaust fan 0.4
Auto cutter machine 15
Spreader machine 0.15
Plotter machine 0.25
Fusing machine 3.5
Sewing machine 0.5
Heat seal machine 2
75
Air compressor
30

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 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022
Load Rating (kW)
Mini boiler 6
Bottle iron 1
Iron table 0.55
Industrial standing fan 0.15
Threat sucker machine 3
Metal detector machine 0.15
Coconut scraping machine 0.5
Hot water boiler 1.5
Fridge 1.5

Fig. 4. Power triangle

The ironing section has nineteen ironing tables with 0.55 However, the grid tie solar system gets disconnected
kW induction motors. Two compressors (75kW and 30kW) during the night when solar power is not available.
are used to provide compressed air for machines. The basic Therefore, a capacitor bank is proposed to generate the
layout diagram of plant two is illustrated in Fig. 2. Section- required reactive power at night.
wise electrical appliances in plants one and two and their A. Capacitor Bank
capacities are listed in Tables I and II, respectively.
A capacitor bank is an arrangement of several capacitors
The Ceylon Electricity Board in Sri Lanka provides used to add kvar to the electrical system, thereby enhancing
electricity to the company under industrial II customer the power factor. Shunt capacitor banks are collections of
category tariff structure. Reactive power demand is currently parallel and series-linked elements. The purpose of designing
billed based on the maximum demand in kilovolt amps a capacitor bank is to calculate the amount of reactive power
(kVA) for each calendar month, which is around 500000 needed in the power system to maintain an improved power
LKR every month. factor.
III. DEMAND ANALYSIS OF THE FACTORY Fig. 4 depicts the power triangle used to calculate how
much reactive power must be added to the system to achieve
A load flow software is used to model and analyze
the target power factor improvement [16]. The capacitor is
electrical system. Power factor, active power, reactive power,
sized using (1) and (2) to regulate the power factor at 0.95 at
and electrical demand are observed under different load
night when the solar system is disconnected from the system.
percentages of the machines in the company. The model is
simulated under various overall load percentages from 40% Q = P (tanθ1 – tanθ2) (1)
to 100% when all loads are connected. The variation of
active power, apparent power, reactive power, and power Q = 3 × V2 × 2ΠfC (2)
factor is listed in Table. III.
The average maximum demand of the company TABLE III. THE SIMULATION DETAILS OF THE OVERALL ELECTRICAL
calculated from past data is about 452 KVA. It is assumed MODEL

that at the peak, all the motors in the factory are loaded. So, Active Apparent Reactive Power
Load
the loading percentage in accordance with the average Power Power Power Factor
category
maximum demand is calculated. In terms of the modeling (kW) (kVA) (kvar) (%)
results shown in [Link], demand falls within the range of 100% 887.5 1047 555.1 84.78
40% to 60% loading categories. The peak loading percentage 90% 782 937.5 517 83.41
for the plant is therefore calculated to be 50%, at which point 80% 490.9 609.1 360 80
the total active and reactive power are 310.5 KW and 330 70% 434.6 561 355 77.4
Kvar, respectively. 60% 372.4 509 347 73.08
In this study, it is assumed that all the motors in operation 50% 310.5 452 330 68
are loaded at the same percentage of full load throughout the 40% 248.4 390 300 63
day. Therefore, the percentage found at the peak is used to
find the average active and reactive power variation with
time as listed in Table. IV.
TABLE IV. POWER CONSUMPTION OF THE FACTORY FOR DIFFERENT
TIMES OF THE DAY
IV. POWER FACTOR CORRECTION
The incorporation of renewable energy sources can Load
Time
reduce grid energy consumption and also results in a Active Power (kW) Reactive Power (kvar)
lowering of electricity bills. Solar photovoltaic systems can 7.30 - 8.30 116.9 71.2
be simply installed on the roofs of both residential and 8.30 – 9.30 303.5 332.9
commercial buildings as grid-connected PV applications. 9.30 – 10.30 303.5 332.9
Also, they can provide power without the use of any harmful 10.30 – 11.30 303.5 332.9
pollutants and can also generate reactive power levels [14], 11.30 – 12.30 303.5 332.9
[15]. Therefore, a solar PV system is used to cater to the 12.30 – 13.30 151.1 177.5
daytime demand of the factory while regulating the power 13.30 – 14.30 278.7 282.7
factor. 14.30 – 15.30 108.5 122.9

ISSN 2756-9160 Page 8

 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022
Load Fig. 5. The block diagram of the solar PV system
Time
Active Power (kW) Reactive Power (kvar)
15.30 – 16.30 261.3 278.9
16.30 – 17.30 261.3 278.9
17.30 – 21.30 52.9 56

Where; P = Active power (kW)

Q = Required reactive power (kvar)
θ1 = Existing power factor angle
θ2 =Improved power factor angle
V = Per phase operating voltage
f = Operating frequency
C = Per phase capacitance Fig. 6. Circuit diagram of the VSC [20]

B. Solar PV System Due to the existence of inductive components in the load,

The DC-DC-AC inverter topology, commonly referred to poor power factor occurs due to high reactive power. As a
as two-stage power conversion, provided the basis for the result, the current-voltage phase difference increases, and the
design of the solar PV system. The block diagram of the power factor is reduced. The power triangle shown in Fig. 4
solar PV system is shown in Fig.5. Solar panels are sized to is used to build the blocks in the PSCAD model.
cater the peak demand of the factory in the daytime. The Incorporating (1), the amount of reactive power required to
DC/DC converter is placed between the solar PV panels and inject into the system to maintain the desired power factor
the voltage source converter to improve voltage gain and improvement of 0.95 is found.
energy collecting capability. A maximum power point
tracking (MPPT) device is connected with the DC/DC The strategy shown in Fig. 7 is used in the PSCAD
converter to maximize the instantaneous DC power output of software to generate reference reactive power. Grid side
the solar PV panel. The MPPT device regulates the DC/DC active and reactive power values (labeled as PP and QQ) are
converter’s duty ratio until the solar PV panel’s DC supply taken to build the power factor control block. Desired
voltage is attained and maintained at its maximum power reactive power level to maintain the power factor at 0.95 is
point voltage. The voltage source converter generates an AC calculated. The error between the desired and the actual
voltage from a DC voltage. reactive power values are fed into a PI controller to generate
the reference for reactive power loops of the VSC. Also,
This study analyzes the controls of the voltage source active power and reactive power change from time to time.
converter to generate the desired reactive power. Therefore, According to the power values, the power factor is
this article does not present the controls and details of the maintained at 0.95 by using the power factor control block.
rest of the system. More details on the grid following
inverter-based solar system can be found in [17], [18].
Voltage-source converter (VSC) converts a DC voltage
into an AC voltage. The inverter is critical in controlling the
solar PV system’s active and reactive power. The circuit
diagram of the VSC is shown in Fig. 6. The dc side voltage
in the converter and the delivered reactive power are
regulated with the support of PI controllers, and they are Fig. 7. Power Factor Control Block
used to generate the reference current for the inner current
loops. The generated ac voltage, on the other hand, is V. RESULTS AND DISCUSSION
connected to the ac system via a low pass filter on the ac side At around 11 am, the maximum average solar power
[19]. generated by a 1 kW solar panel is 504.116 W, and at that
period, the maximum active power of the factory is observed
Certain characteristics of reactive power compensation
at around 278.77 kW. Therefore, the combination of the 40
with voltage source converter (VSC) technology can be
kvar capacitor bank and the 553 kW solar PV system is
favorable to overall system performance. Voltage source
proposed, and it improves the power factor of the factory
converters (VSC) are utilized with series-connected insulated
from 68% to 95%. Fig. 8 illustrates the improved power
gate bipolar transistors (IGBT). VSC can generate reactive
factor after the power factor corrections.
power by the use of freewheeling diodes on each of the
power switches. Table. V compares the simulation and calculated power
flow at the main circuit breaker in all time slots after
introducing the power factor improvement methods.
Calculated power values are slightly different from the
software’s simulation result values because of the internal
losses in the simulated circuits. The plant is open at 7.30 am,
and operations continue until 9.30 pm. From 7.30 am to 5.30
pm, approximately all the sections are operating at their
maximum efficiency.

ISSN 2756-9160 Page 9

 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022

Fig. 8. Power Factor Improvement

TABLE V. COMPARISON OF THE SIMULATION RESULT WITH THE CALCULATED RESULT

Load Solar Calculated Simulated PF
Active power Reactive Power Power Active Reactive Power Active power Reactive Power
Time kW kVAr kW power kVAr kW kVAr
kW
7:30-8:30 116.9 71.2 103.63 13.27 3.86 15.12 5.56 0.95
8:30-9:30 303.5 332.9 185.84 177.66 91.66 169.3 88 0.945
9:30-10:30 303.5 332.9 260.9 42.58 33.17 38.53 30 0.946
10:30-11:30 303.5 332.9 275.5 31.99 21.80 29.8 19 0.948
11:30-12:30 303.5 332.9 278.77 27.72 19.26 24.71 17 0.951
12:30-13:30 151.1 177.5 262.26 111.16 96.92 105.2 91.25 0.946
13:30-14:30 278.7 282.7 201.8 76.87 53.16 82.43 56.04 0.953
14:30-15:30 108.5 122.9 159.83 51.34 41.56 46.71 38.51 0.945
15:30-16:30 261.3 278.9 111.49 149.8 102.3 155.5 108.0 0.946
16:30-17:30 261.3 278.9 35.94 225.3 165 229.5 169.1 0.946
17:30-21:30 52.9 56 - - - 51.89 16.49 0.96
The integration of renewable energy sources reduces
energy consumption from the CEB. The company’s typical
maximum demand, based on historical data, is around 452
KVA and, after power factor corrections, it reduces to 274
KVA, which is about a 39% reduction. Fig. 9 illustrates the
active power and reactive power values after the integration
of the capacitor bank and the solar panel.

TABLE VI. COST REDUCTION DETAILS WITH THE POWER FACTOR

IMPROVEMENT

Maximum Cost for

Power Cost per unit
Demand Maximum
Factor (LKR)
(kVA) Demand (LKR)
0.68 452 1100 497200
Fig. 9. Active power and Reactive power 0.95 274 1100 301400

At that period, a solar PV system maintains a 95% power

factor by providing the required reactive power to the
system. From 5.30 pm to 9.30 pm, when the solar system is
disconnected from the system, only the packing section of Under the industrial consumer II tariff structure, the
the factory is operated. The required reactive power is low at maximum demand penalty paid by the company to the
that time and the capacitor bank improves the power factor Ceylon Electricity Board is 1100 LKR per kVA. It accounts
up to 97%. After 9.30 pm, every machine is powered off, and for 497,200 LKR each month on average, with a maximum
only LED security lights are operated until 6.00 am of the demand of 452 kVA as listed in Table. VI.
next day. During that period, energy consumption is very Power factor improvement of 0.95 is preferred because it
low, and it is assumed it is zero. Therefore, it is better to saves more energy and allows for less over-correcting
switch off the capacitor bank from 9.30 pm to 7.30 am, throughout the day when all loads are running. Also, the
which can be facilitated by a breaker controlled by a timer reactive power consumption of motors is roughly consistent
connected to a relay. with the load compared to the active power requirement.

ISSN 2756-9160 Page 10

 INTERNATIONAL CONFERENCE ON ADVANCES IN TECHNOLOGY AND COMPUTING
(ICATC-2022)
Faculty of Computing and Technology (FCT), University of Kelaniya, Sri Lanka
3rd December 2022
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